The Ultimate Guide to Conveyor Systems

The Ultimate Guide to Conveyor Systems

View Details

A conveyor system is a mechanical device used to move materials from one place to another. These systems are prevalent in the material handling and packaging industries for transporting bulky or heavy items, thereby minimizing human error, lowering workplace risks, and reducing labor costs.

Working of a Conveyor System

Conveyor systems play a crucial role in production processes. Understanding how each component fits together is vital when discussing the workings of these systems.

How a Conveyor System Works

This section focuses primarily on belt conveying systems, the most common type, to narrow down the topic of conveying systems.

Belt:
A belt conveyor system utilizes thick, durable belts looped over pulleys. When the motor is activated, the belt moves between the pulleys.

Pulleys:
A conveyor belt system requires a driving pulley and a return pulley to manage the belt's movement.

Belt Cleaner:
Belt cleaners remove any carryback object left on a belt after a load has been unloaded.

Drive:
The belt drive can be located in various spots on a conveyor based on its design. Most belt conveyors employ AC motors to power the pulleys that move the belts.

Types of Conveyor Systems

There are multiple types of conveyors, with three of the most common being overhead, belt, and roller conveyors. Among these, overhead conveyors are quite versatile.

Belt Conveyors
The belt conveyor is the most simple and popular type. It consists of a belt that moves on a series of rollers or belt-style supports to facilitate the movement of materials.

Gravity Roller Conveyors
Gravity roller conveyors feature a set of rollers connected to a side frame. When tilted or angled, gravity helps move various-sized items along the conveyor. Shipping companies commonly use these for loading and unloading trucks.

Chain Conveyors
Chain conveyors have multiple chains that come into contact with the items being transported. These conveyors are ideal for items with uneven bottoms or very heavy products.

Motorized Roller Conveyors
These conveyors utilize motors to power evenly spaced rollers. The design often resembles that of gravity conveyors, connected by a chain or belt, and sometimes features sensors to prevent pieces from getting packed together.

Slat Conveyors
Used mainly for assembly applications, slat conveyors can be loaded and unloaded with robotic automation. Their smooth surface helps prevent damage to the items being moved.

Overhead Conveyor Systems

Overhead conveyor systems come in various types, each with unique designs but similar functions.

• Enclosed Track Conveyor: This type features an enclosure that covers the trolley connectors, making it easier to incorporate bends and curves.
• Open Track Conveyor: Suitable for long straight configurations, these do not cover the track.
• Chain Overhead Conveyor: These use a powered chain with pendants or pusher dogs, ideal for intricate paths.

Monorail Conveyors
Monorail conveyors utilize space above production areas and are powered by signal lines from conductor lines inside mounted rails. They move carriers upward out of the way and then descend them to the required level.

Power and Free Conveyors
These systems transport parts through manufacturing and assembly processes, allowing finished products to move from station to station while being worked on. They are a specialized type of overhead conveyor.

Inverted Conveyors
Inverted conveyors are used for power and free conveyance and typically do not utilize belts or chains.

Paternoster Conveyors
Also known as platform conveyors, patenoste conveyors are vertical systems that use platform carriers attached to a chain drive.

Chute Conveyors
Constructed from wood, metal, or plastic, these have an angled surface for items to slide down.

Screw Conveyors
These conveyors move bulk substances like granular products and loose materials. The system's core element is a rotating helicoid inside a pipe, often referred to as an auger or spiral conveyor.

Pneumatic Conveyors
Used for transporting bulk commodities, pneumatic conveyors rely on pressurized gas to push materials through a sealed pipeline.

Vibratory Conveyors
Using vibrations to move materials along a trough, these are ideal for grains, food products, and mined materials. They are designed to operate in harsh environments.

Chain on Edge Conveyors (COE)
This single-strand chain conveyor can flex along the horizontal axis and make both horizontal and vertical turns, providing versatility over traditional chain-driven conveyors.

Skid Conveyors
Utilized for transporting products on fixtures with runners called skids, these conveyors are valued for their efficiency and quiet operation.

Friction Conveying System

A safer alternative to power and free systems, friction conveyors feature a friction drive, load-bearing track, switch, stopper, trolley, and steel structure, operating cleanly and quietly.

Why Conveyor Systems are Crucial to Industrial Automation

Conveyor systems can be employed in numerous industrial sectors, including production, packaging, and delivery.

Reduces Manual Waste

Automating certain tasks can significantly reduce manual labor. Conveyors enhance production line efficiency and productivity.

Provides Flexibility

Modular conveyors offer flexibility for various applications and are easy to install.

Enhances Quality Control

Automation aids in identifying defects and correctly orienting products for subsequent processes, improving efficiency.

Conveyor systems integrate well with various manufacturing technologies, providing key advantages.

Application Systems for Conveyors

Conveyors are used across industries like food production, automotive, pharmaceuticals, aerospace, and chemicals for buffering, storage, and transportation.

Benefits of the Conveyor System

Conveyors offer several advantages, including:

• Cost-effective for transporting materials over long distances.
• Visible material during conveying and adjustable height.
• Equipped with metal separators and trippers for versatile unloading.
• Allows for arc movement and sidewalls to prevent spillage.
• Can include weigh-belt sections for continuous product weighing.

Cons of the Conveyor System

Despite their benefits, conveyors have some drawbacks:

• Open design, risking product fall unless covers are installed.
• Sticky materials may adhere to various parts, requiring frequent cleaning.
• Challenging to clean belts, sometimes necessitating replacement.
• Discharge often results in material loss, causing maintenance issues.
• Difficult to control odors.

SUMMARY

Conveyor systems are indispensable across diverse sectors. They help in various tasks, offering flexibility and safe operational procedures, thus enhancing efficiency and cost-effectiveness.

Choosing the Right Conveyor

To select the appropriate conveyor system, several criteria must be considered:

The first crucial factor is load capacity. Next, consider the conveying route to be established. The types of products and their characteristics (weight, volume, and condition) are also significant. Additionally, consider the technology suitable for your installation and the space configuration. If ground installation is not feasible, an overhead conveyor could be ideal.

The company is the world’s best Conveyor Components supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.